Formed Stud with Integral Diaphragm Section

ABSTRACT

The invention relates generally to building construction, and more particularly to studs for use in wall panels used in the construction of foundation walls and upper floor exterior walls. The invention provides a structural wall system to support building loads and lateral earth pressure from adjacent ground, said system comprising a wall assembly using plurality of studs preferably formed from metal located side by side and each having a cross section comprising an orthogonal lip section with interior flange section, a web section, and an exterior diaphragm section orthogonal to the web section and having a first recessed shoulder on the open distal end and a second recessed shoulder on the bend line integral with the web section. The wall system may be assembled using a standard steel channel as a starting point. The stud diaphragm of the present invention extends laterally from the web portion with the distal edge to be aligned with and fastened to the standard steel channel. A second stud is then installed by aligning and fastening the distal edge of such stud to the second recessed shoulder of the preceding stud to form a continuous diaphragm surface as studs are similarly connected to one another.

FIELD OF THE INVENTION

The invention relates generally to building construction, and moreparticularly to studs for use in wall panels used in the construction offoundation walls and upper floor exterior walls.

BACKGROUND OF THE INVENTION

A proper foundation of a building means not only insulating to saveenergy, but also providing effective structural design as well asmoisture, termite, and radon control techniques where appropriate. Thethree basic types of foundations include full basement, crawl space, andslab-on grade. Actual buildings may include combinations of these types.In cases of a full basement, crawl space, a structural perimeterfoundation wall is employed as a structural element transferringbuilding and service loads to the foundation.

The most common perimeter structural wall systems for foundation wallsinclude cast-in-place concrete, concrete block foundation wall,insulated concrete form systems, pressure-preservative-treated woodfoundations, precast concrete foundation walls, masonry or concretepiers, cast-in-place concrete sandwich panels, and various masonrysystems. Steel panel perimeter foundation walls are also known, such asthe AnchorPanel assemblies by Fast Track Foundation Systems. These arecorrugated steel panels that can be cut to length and installed with lagscrews hanging under the perimeter floor boards of a pier-supportedstructure. The corrugated shape provides stiffening against bendingunder vertical and side loads. Another panel system is disclosed in U.S.Pat. No. 8,307,608, describing a modular wall panel have a wall face, atop cap, a bottom pan and two side framing studs at the perimeter sidesextending vertically from the bottom pan to the top cap are allconstructed integrally.

Cast-in-place concrete and concrete block foundation wall systems arecostly and complex to assemble without special skills and tools. Asecond non-load-bearing wall system is required and assembled from woodor light gauge steel adjacent to the interior face of the cast-in-placeconcrete and concrete block foundation wall to form a receptacle forinsulation and provide a furring strip for securing interior sheathingmaterials. This further adds to the complexity and expense of this typewall system.

Problems associated with the systems in the prior art generally pertainto cost and complexity of assembly, but also include lack of flexibilityto accommodate design changes in the field.

Insulated concrete forms (ICF) provide an alternative to traditionalstructural wall systems. They are made of stiff foam forms that keepconcrete in place as it cures. They remain in the foundation to serve asinsulation after construction is completed. Although building with ICFcan help improve a home's energy efficiency, there are disadvantages tousing them, such as cost, difficulty to remodel, increased footprint toaccommodate the total wall thickness, nesting for insects and routingfor groundwater to enter the walls.

Steel panel perimeter foundation walls known in the art havedisadvantages of cost and complexity of design. They lack flexibility toaccommodate changes in the field.

It is therefore a primary feature of the present invention to overcomethe problems in the prior art. It is a further feature of the presentinvention to provide a structural wall system that may be assembled inthe field or pre-assembled as a panel system for use a subgradestructural foundation wall system or an above grade structural wallsystem that is cost effective, simple to install, and accommodatesdesign changes in the field.

DISCLOSURE OF INVENTION

The invention provides a structural wall system to support buildingloads and lateral earth pressure from adjacent ground, said systemcomprising a wall assembly using plurality of studs preferably formedfrom metal located side by side and each having a cross sectioncomprising an orthogonal lip section with interior flange section, a websection, and an exterior diaphragm section orthogonal to the web sectionand having a first recessed shoulder on the open distal end and a secondrecessed shoulder on the bend line integral with the web section. Thewall system may be assembled using a standard steel channel as astarting point. The stud diaphragm of the present invention extendslaterally from the web portion with the distal edge to be aligned withand fastened to the standard steel channel. A second stud is theninstalled by aligning and fastening the distal edge of such stud to thesecond recessed shoulder of the preceding stud to form a continuousdiaphragm surface as studs are similarly connected to one another. Thealignment of the second stud on the second recessed shoulder may beadjusted to ensure the second stud is preferably perpendicularly plumbto grade.

A plurality of studs may be assembled one after another on the site, orpre-assembled into modular units. The stud web section may have matchingbolt holes to allow another unit to be joined to the unit on either sideto form a section of vertical wall.

Once the studs are assembled into a wall system, the continuousdiaphragm section acts as a shear wall to provide reactions for roof andfloor diaphragms and to transmit forces into the foundation.

The stud interior flange section may be used for securing finishsheathing, or for further attaching a sheathing support element such asa steel resilient channel known in the art. The interior flange sectionis formed orthogonal to the web section and preferably in the samedirection as the exterior diaphragm section.

Two or more studs may be assembled to form an internal corner orexternal corner. Other standard c-channel steel sections may beincorporated to complete the corner in a manner to provide an interiorflange surface for securing finish sheathing. Alternatively, a steelcorner fabrication may also be incorporated to complete the corner in amanner to provide an interior flange surface for securing finishsheathing.

The stud may further have integrally formed web stiffeners and diaphragmstiffeners to augment the structural loading capacity of the stud. Thediaphragm stiffener is preferably the same depth as the recess shoulderso that a panel may be cut in the field and fastened to an adjacentpanel while maintaining a general planar surface of the exterior wallsystem.

The stud may have integrally formed holes through the web to provide forpassage of utilities. Holes are preferably located at the neutral axisof the web and are of a size to allow passage of electrical or otherutilities without affecting the minimum required structural capacity ofthe stud.

The wall system is installed using top and bottom metal tracks. Eachtrack has a web section and a flange on either side of the web section.The bottom track is bolted or otherwise fastened through the web to thefoundation footing and receives the studs where they are fastenedthrough the interior and exterior flanges of the track. The top track isattached on top of the studs where they are fastened through theinterior and exterior flanges of the track. A top plate preferably madeof wood is then bolted or otherwise fastened to the top track to form abase for attaching a floor system.

To control air and moisture infiltration, a gasket in tape, sheet orcaulking form and suitable to restrict moisture infiltration may beapplied between fastened surfaces, including between the bottom trackand footing, and between the overlapping joints of fastened studs.Suitable gasket materials include butyl tape or caulking, polyurethanecaulking, polyethylene foam, asphalt, rubber and the like.

To further control air and moisture infiltration, a barrier in sheet,spray, or roll-on form may be applied over the exterior continuousplanar surface of the wall system. Heavy textured plastic or rubbermembranes placed against the foundation wall form a drainage layer toconduct roof spillage or ground water down the exterior foundation walland into a drain system to carry water safely away from the building.The use of a plastic membrane, protected by a geotextile to combine goodwater drainage down the foundation wall (and into the footing drains)with gravel backfill to nearly the top of grade is also suitable to theinvention. Suitable barrier materials include SBS rubberized asphaltcompound integrally laminated to a blue, high density cross-laminatedpolyethylene film, rubberized compounds in liquid form, thermoplasticsheets and the like.

The exterior wall surface may be insulated to restrict heat transferthrough the wall system. Suitable insulation materials include rigidfoam from at least 1-inch thick and preferably 2.5 inches thick.Material categories for rigid foam insulation include polystyrene,polyurethane, icynene, and the like.

Two adjacent stud web sections define a cavity for receiving interiorinsulation. Interior insulation may be selected from a wide range ofmaterials, including fibreglass batt, mineral batt, rigid foam, sprayfoam and the like.

The stud interior flange section defines a surface where interiorsheathing may be fastened directly, or to furring strips previouslyfastened to the stud interior flange section.

Preferably, the studs of the wall assembly are manufactured from a metalor a metal alloy, such as flat rolled steel with galvanized or organiccoatings to prevent corrosion. The flat rolled steel may be selectedfrom commercial or structural grades with minimum yield strength from 33ksi to 80 ksi, and preferably 50 ksi. The studs of the wall arepreferably manufactured using light gauge galvanized steel in thicknessof between 1 mm and 4 mm with 1.42 mm to 2 mm preferred, to provide alightweight structure for ease of assembly of a wall and satisfyingstructural performance conditions required by applicable buildingregulations.

Where flat rolled steel is used with galvanized or organic coatings toprevent corrosion, zinc or other suitable anodes may be furtherconnected to the wall system to provide additional corrosion protection.

The wall assembly is preferably fastened together using galvanized selfdrilling self tapping screws, but may be fastened using alternativemeans such as bolts with nuts, welding, rivets, toggle lock or the like.

The wall assembly may be structurally designed at various heights. Thespecific structural design is based on general engineering principlesand local building regulations.

The present invention also provides a method for assembling a wallassembly in accordance with the present invention; on top of a suitablesupport structure which may comprise a concrete footing, beam supports,column supports, wall supports or combinations thereof; which methodcomprises the steps of a) intercalating a pair of adjacent studs innesting engagement and b) fastening the studs to each other to create acontinuous wall surface.

Before explaining at least one embodiment of the invention in detail, itis to be understood that the invention is not limited in its applicationto the details of construction and to the arrangements of the componentsset forth in the following description or illustrated in the drawings.The invention is capable of other embodiments and of being practiced andcarried out in various ways. Also, it is to be understood that thephraseology and terminology employed herein are for the purpose ofdescription and should not be regarded as limiting. As such, thoseskilled in the art will appreciate that the conception, upon which thisdisclosure is based, may readily be utilized as a basis for thedesigning of other structures, methods and systems for carrying out theseveral purposes of the present invention. It is important, therefore,that the claims be regarded as including such equivalent constructionsinsofar as they do not depart from the spirit and scope of the presentinvention.

DETAILED DESCRIPTION

FIG. 1 is a cross sectional schematic showing one embodiment of thepresent invention.

FIG. 2 is a cross sectional schematic showing a second embodiment of thepresent invention.

FIG. 3. is a cross-sectional schematic showing multiple studs added sideby side to the wall assembly.

FIG. 4. is a perspective view schematic showing one embodiment of thestructural system assembled as a wall.

FIG. 5. is a cross-sectional schematic showing one embodiment of theinvention in a completed wall assembly.

FIG. 6. is a cross-sectional schematic showing one embodiment of theinvention in a completed corner wall assembly.

FIG. 7. is a cross-sectional schematic showing one embodiment of theinvention in a completed corner wall assembly.

Although embodiments of the present invention described herein aregenerally described as providing a wall structure for a building, itwill be apparent to one of ordinary skill in the art than otherembodiments of the present invention can be similarly used to provide afloor, roof or ceiling structure for a building.

Referring to FIG. 1, a stud 100 for use in a wall assembly comprises anorthogonal lip section 110 with interior flange section 120, a websection 130, and an exterior diaphragm section 150 orthogonal to the websection and having a first recessed shoulder 160 on the open distal endand a second recessed shoulder 140 on the bend line integral with theweb section. The interior flange section 120 is formed in the samedirection as the diaphragm 150 to depict a “C” appearance with the websection 130. It will be appreciated that the studs are of indeterminatelength L and may be customized to the length required. The exteriordiaphragm 150 extends outwardly from the web portion 130 and theincluded angle between the diaphragm portion 150 and web portion 130 istypically 90 degrees, although other angles may be incorporated. Thediaphragm 150 is provided with a stiffener 180 at spaced locations alongthe length L that are orthogonal to the web section 130 respectively.The web section 130 is provided with a stiffener 170 at spaced locationsalong the length L that are orthogonal to the diaphragm. The stud 100 isformed from a rolled steel strip of appropriate gauge and the studs 100may be pre-finished by painting, powder coating or galvanising toinhibit corrosion.

Referring to FIG. 2, a stud 100 for use in a wall assembly comprises anorthogonal lip section 110 with interior flange section 120′, a websection 130, and an exterior diaphragm section 150 orthogonal to the websection and having a first recessed shoulder 160 on the open distal endand a second recessed shoulder 140 on the bend line integral with theweb section. The interior flange section 120 is formed in the oppositedirection as the diaphragm 150 to depict an “S” appearance with the websection 130. It will be appreciated that the studs are of indeterminatelength L and may be customized to the length required. The exteriordiaphragm 150 extends outwardly from the web portion 130 and theincluded angle between the diaphragm portion 150 and web portion 130 istypically 90 degrees, although other angles may be incorporated. Thediaphragm 150 is provided with a stiffener 180 at spaced locations alongthe length L that are orthogonal to the web section 130 respectively.The web section 130 is provided with a stiffener 170 at spaced locationsalong the length L that are orthogonal to the diaphragm. The stud 100 isformed from a rolled steel strip of appropriate gauge and the studs 100may be pre-finished by painting, powder coating or galvanising toinhibit corrosion.

Referring to FIG. 3, the studs 100 may be added side by side to the wallassembly 400 to provide a diaphragm of the required width and length.The individual studs are relatively light to handle and assemble butprovide high strength and rigidity when in place. The studs 100 may befastened together with mechanical fasteners 300, such as screws, bolts,clips or rivets, or may be permanently connected, as for example bywelding. In typical applications for a residential wall, the studs 100are formed from rolled steel strip having a thickness of between 1 mmand 3 mm with 1.42 mm to 2 mm preferred. The diaphragm section 150 has alateral extent dependent on structural requirements, and is typicallybetween 10 inches and 16 inches, and preferably 12 inches. The web 130has a height of between 3½ inches and 10 inches with a preferred heightof 6¼ inches. In a nested arrangement, the spacing between adjacent webportions is dependent on structural requirements, and is typicallybetween 10 inches and 14.5 inches, and preferably 10 inches. Thedimensions may be varied to suit the loading and the unsupported span asper normal engineering practices.

Referring to FIG. 4, the studs 100 may be added side by side to the wallassembly 400 to provide a diaphragm of the required width and length.The wall assembly is fastened to a bottom track 600 that is itselffastened to a footing 700 using mechanical fasteners such as bolts withnuts, adhesive, or a combination thereof a bottom track 600. The wallassembly is secured at the top using a top track 500. The diaphragm 150is provided with a stiffener 180 at spaced locations along the length Lthat are orthogonal to the web section 130 respectively. The web section130 is provided with a stiffener 170 at spaced locations along thelength L that are orthogonal to the diaphragm. The stud 100 is formedfrom a rolled steel strip of appropriate gauge and the studs 100 may bepre-finished by painting, powder coating or galvanising to inhibitcorrosion. The first recessed shoulder 160 of the diaphragm 150 isnested on the second recessed shoulder 140 and fastened using mechanicalfasteners 300 in periodic spacing to each other along the length L ofthe stud and across the top track 500 and bottom track 600.

Referring to FIG. 4, to further control air and moisture infiltration, abarrier system 800 in sheet, spray, composite or roll-on form may beapplied over the exterior continuous planar surface of the wall system.Heavy textured plastic or rubber membranes 800 placed against thefoundation wall form a drainage layer to conduct roof spillage or groundwater down the exterior foundation wall and into a drain system to carrywater safely away from the building. To restrict heat transfer throughthe wall assembly 400, an insulation system 900 may be applied to thecomplete exterior wall surface. The insulation system 900 may be adheredor otherwise fastened to the complete exterior wall surface. Suitableinsulation materials 900 include rigid foam from at least 1-inch thick,and preferably 2.5 inches thick. Material categories for rigid foaminsulation include polystyrene, polyurethane, icynene, and the like.

Referring to FIG. 4, a gasket 720 in tape, sheet or caulking form andsuitable to restrict moisture infiltration may be applied betweenfastened surfaces, including between the bottom track and footing, andbetween the overlapping joints of fastened studs.

Referring to FIG. 4, the wall system 400 may be assembled using astandard steel channel 920 as a starting point. The stud diaphragm 150of the present invention extends laterally from the web portion with thefirst recessed shoulder 160 to be aligned with and fastened to thestandard steel channel 920. A second stud 100 is then installed byaligning and fastening the distal edge of such stud to the secondrecessed shoulder 140 of the preceding stud to form a continuousdiaphragm surface as studs are similarly connected to one another.

Referring to FIG. 5, the studs 100 may be added side by side to the wallassembly 400 to provide a diaphragm of the required width and length.The individual studs are relatively light to handle and assemble butprovide high strength and rigidity when in place. The studs 100 may befastened together with mechanical fasteners 300, such as screws, bolts,clips or rivets, or may be permanently connected, as for example bywelding. Two adjacent stud web sections 130 define a cavity 940 forreceiving interior insulation 960. Interior insulation 960 may beselected from a wide range of materials, including fibreglass batt,mineral batt, rigid foam, spray foam and the like. The stud interiorflange section 120 defines a surface where interior finish sheathing 980such as drywall may be fastened. A gasket 720 in tape, sheet or caulkingform and suitable to restrict moisture infiltration may be appliedbetween fastened surfaces, including between the bottom track 600 andfooting 700, and between the overlapping joints of fastened studs. Abarrier system 800 in sheet, spray, composite or roll-on form may beapplied over the exterior continuous planar surface of the wall system400. Heavy textured plastic or rubber membranes 800 placed against thefoundation wall 400 form a drainage layer to conduct roof spillage orground water down the exterior foundation wall and into a drain systemto carry water safely away from the building. To restrict heat transferthrough the wall assembly 400, an insulation system 900 may be appliedto the complete exterior wall surface. The insulation system 900 may beadhered or otherwise fastened to the complete exterior wall surface.Suitable insulation materials 900 include rigid foam from at least1-inch thick, and preferably 2.5 inches thick.

Referring to FIG. 6, the studs 100 may be added to the wall assembly 400to provide an internal corner assembly 1000 and external corner assembly1010. Stud 100 may have an interior flange section 120 for securingfinish sheathing. Standard steel c-channel fabrications 200 may beemployed to provide for corner support and a surface 122 for securingfinish interior sheathing.

Referring to FIG. 7, the studs 100 may be added to the wall assembly 400to provide an internal corner assembly 1000 and external corner assembly1010. Stud 100 may have an interior flange section 124 for securingfinish sheathing.

Alternatively, a steel corner fabrication may also be incorporated tocomplete the corner in a manner to provide an interior flange surfacefor securing finish sheathing.

Referring to FIG. 8, the studs 100 may be added side by side to the wallassembly 440 to provide a diaphragm of the required width and length.The wall assembly is fastened to a bottom track 600 that is itselffastened to a floor system 720 using mechanical fasteners such as boltswith nuts, adhesive, or a combination thereof. The wall assembly issecured at the top using a top track 500. The diaphragm 150 is providedwith a stiffener 180 at spaced locations along the length L that areorthogonal to the web section 130 respectively. The web section 130 isprovided with a stiffener 170 at spaced locations along the length Lthat are orthogonal to the diaphragm. The stud 100 is formed from arolled steel strip of appropriate gauge and the studs 100 may bepre-finished by painting, powder coating or galvanising to inhibitcorrosion. The first recessed shoulder 160 of the diaphragm 150 isnested on the second recessed shoulder 140 and fastened using mechanicalfasteners 300 in periodic spacing to each other along the length L ofthe stud and across the top track 500 and bottom track 600.

Referring to FIG. 8, to further control air and moisture infiltration, abarrier system 820 in sheet, sheathing, film, membrane or other form maybe applied over the exterior continuous planar surface of the wallsystem. A drainage layer may also be installed to conduct roof spillageor infiltrated water down the exterior wall and into a drain system tocarry water safely away from the building. To restrict heat transferthrough the wall assembly 400, an insulation system 900 may be appliedto the complete exterior wall surface. The insulation system 900 may beadhered or otherwise fastened to the complete exterior wall surface.

Suitable insulation materials 900 include rigid foam from at least1-inch thick, and preferably 2.5 inches thick. Material categories forrigid foam insulation include polystyrene, polyurethane, icynene, andthe like.

Referring to FIG. 8, a gasket 720 in tape, sheet or caulking form andsuitable to restrict moisture infiltration may be applied betweenfastened surfaces, including between the bottom track and subfloor 720,and between the overlapping joints of fastened studs.

Referring to FIG. 8, the wall system 400 may be assembled using astandard steel channel 920 as a starting point. The stud diaphragm 150of the present invention extends laterally from the web portion with thefirst recessed shoulder 160 to be aligned with and fastened to thestandard steel channel 920. A second stud 100 is then installed byaligning and fastening the distal edge of such stud to the secondrecessed shoulder 140 of the preceding stud to form a continuousdiaphragm surface as studs are similarly connected to one another.

The dimensions of the stud 100 may be varied to suit the loading and theunsupported span as per normal engineering practices. The materialthickness of each modular element remains constant to within normalproduction tolerances. The particular design of the stud, web stiffener,the transverse stiffener, and diaphragm element are selected to satisfystructural conditions due to static and dynamic-loading in accordancewith local building regulations and normal engineering practices,including the maximum vertical displacement across the particularelement; and maximum permissible slopes, moments, stresses, and shearforces for the particular element. In addition, the layout of the stud,the transverse stiffener, and diaphragm element relative to each othermay be designed to limit the maximum permissible stresses ordisplacement of any single element.

Preferably the steel material material conforms to ASTM A653 with a G90galvanized coating, although galvanized coatings of lesser or morethickness can be employed to suit particular service conditions. Theoffset of the first recessed shoulder 160 from the main diaphragm ispreferably ¼ inch, and that of the second recessed shoulder 140correspondingly reduced by the thickness of the material. It is to beunderstood that the invention is not limited in its application to thedetails of construction and to the arrangements of the components setforth in the following description or illustrated in the drawings. Theinvention is capable of other embodiments and of being practiced andcarried out in various ways to adapt to current and future buildingenvelope designs comprising sheathing, air and vapour barriers, andinsulation technologies. Also, it is to be understood that thephraseology and terminology employed herein are for the purpose ofdescription and should not be regarded as limiting. As such, thoseskilled in the art will appreciate that the conception, upon which thisdisclosure is based, may readily be utilized as a basis for thedesigning of other structures, methods and systems for carrying out theseveral purposes of the present invention. It is important, therefore,that the claims be regarded as including such equivalent constructionsinsofar as they do not depart from the spirit and scope of the presentinvention.

What is claimed is:
 1. A structural wall panel system comprising anassembly using a standard steel channel and a plurality of studs formedfrom metal located side by side and each having a cross sectioncomprising an orthogonal lip section with interior flange section, a websection, and an exterior diaphragm section orthogonal to the web sectionand having a first recessed shoulder on the open distal end and a secondrecessed shoulder on the bend line integral with the web section,wherein the stud extends laterally from the web portion with the distaledge to be aligned with and fastened to the standard steel channel, andadditional studs are installed by aligning and fastening the distal edgeof each successive stud to the second recessed shoulder of the precedingstud to form a continuous diaphragm surface as studs are similarlyconnected to one another.